System and method for fabricating a dental restoration

ABSTRACT

A system for fabricating a dental restoration to restore a tooth at a restoration site in a dentition of a patient is disclosed. The dentition includes a restoration dental arch and an opposing dental arch. The restoration dental arch include the restoration site and the opposing dental arch is opposite the restoration dental arch. The system includes an impression apparatus, a motion capture apparatus, an interface apparatus, and a restoration design system. The impression apparatus is configured to capture an impression of the dentition of the patient. The motion capture apparatus is configured to capture a plurality of location data points that represent the locations of the opposing dental arch relative to the restoration dental arch. The interference model generation system is configured to generate an interference model for the restoration site. The restoration design system is for designing a restoration using the interference model.

CROSS REFERENCE TO RELATED APPLICATIONS

This application is a continuation of U.S. patent application Ser. No.14/695,353, filed on Apr. 24, 2015, entitled SYSTEM AND METHOD FORFABRICATING A DENTAL RESTORATION, which claims priority to U.S.Provisional Patent Application No. 61/983,888 filed on Apr. 24, 2014,entitled SYSTEM AND METHOD FOR FABRICATING A DENTAL RESTORATION, thedisclosures of which are hereby incorporated by reference in theirentireties.

BACKGROUND

Teeth are typically classified as anterior or posterior. Anterior teethare in the front of the mouth; posterior teeth are in the back of themouth. Typically, a patient has six upper anterior teeth and six loweranterior teeth. The anterior teeth usually have a narrow incisal edge.In a patient who has a normal bite relationship, the incisal edges ofthe upper anterior teeth are positioned slightly further towards thefront of the patient's mouth than the incisal edges of the loweranterior teeth. In this arrangement, the incisal edge of the loweranterior teeth may contact the rear-facing (or lingual) surface of theupper anterior teeth.

A patient can have as many as ten upper posterior teeth and ten lowerposterior teeth, although it is quite common to have fewer (e.g., wisdomteeth are frequently removed). The posterior teeth have an occlusalsurface that faces the teeth on the opposite arch and forms the bitingsurface.

A dental restoration is used to restore a tooth or multiple teeth. Forexample, a crown is a dental restoration that is used to restore asingle tooth. A bridge is another example of a dental restoration. Abridge restores multiple teeth. In some circumstances, dentalrestorations are used to restore functionality after a tooth is damaged.In other circumstances, dental restorations are used to aestheticallyimprove a patient's dentition.

Generally, a dental restoration must fit harmoniously with the patient'ssurrounding dentition, and especially with the opposing dentition. Forexample, the occlusal surface (i.e., the biting surface) of arestoration should be carefully designed to avoid interfering with theclosure and movement of the jaw.

SUMMARY

In general terms, this disclosure is directed to a system and method forsimulating occlusal interference using a functional bite map. In onepossible configuration and by non-limiting example, a dental restorationis compared to an interference surface generated from a functional bitemap to identify occlusal interference regions.

One aspect is a system for fabricating a dental restoration to restore atooth at a restoration site in a dentition of a patient, wherein thedentition includes a restoration dental arch and an opposing dentalarch, the restoration dental arch including the restoration site and theopposing dental arch being opposite the restoration dental arch,comprising: an impression apparatus configured to capture an impressionof the dentition of the patient, the portion of the dentition includingthe restoration site; a motion capture apparatus configured to capture aplurality of location data points, the location data points representingthe locations of the opposing dental arch relative to the restorationdental arch as the dentition moves between a plurality of bitepositions; an interference model generation system configured togenerate an interference model for the restoration site, wherein theinterference model includes an interference surface, the interferencesurface corresponding to the locations of a portion of the opposingdental arch in at least a portion of the plurality of the locationsrepresented by the plurality of location data points; and a restorationdesign system for designing a restoration using the interference model.

Another aspect is a method of generating a dental restoration for apatient, comprising: generating an interference model from an impressionand a functional bite map, the impression representing at least aportion of a dentition of the patient, the functional bite maprepresenting bite registration information for a plurality of positionsof the dentition of the patient; aligning the interference model to arestoration site of the patient; and designing a dental restoration forthe restoration site using the interference model.

Yet another aspect is a method of generating a dental restoration torestore an anterior tooth of a patient, comprising: generating anincisal guide path, using a computing device, corresponding to thelingual surface of the anterior tooth; fabricating an incisal guide pathstructure based on the incisal guide path; and using the incisal guidepath structure to generate the dental restoration.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a schematic block diagram illustrating an example of a systemfor simulating occlusal interference using a functional bite map.

FIG. 2 illustrates an example architecture of a computing device, whichcan be used to implement aspects according to the present disclosure.

FIG. 3 is a flow chart illustrating an example method of capturing adental impression using embodiments of the system of FIG. 1.

FIG. 4 is an example process performed at some embodiments of the motioncapture station 106 of FIG. 1.

FIG. 5 is an example embodiment of a bite capture apparatus forcapturing the functional bite map of FIG. 1.

FIG. 6 is an illustration of an embodiment of the bite capture apparatusof FIG. 5 being used to capture bite motion information of a patient.

FIG. 7 is an illustration of an embodiment of the bite capture apparatusof FIG. 5 after the securing layer has formed to the patient'sdentition.

FIG. 8 is an illustration of an embodiment of the bite capture apparatusof FIG. 5 after the motion capture layer has captured the relativemotion from the patient's dentition.

FIG. 9 is another example embodiment of a bite capture apparatus forcapturing the functional bite map of FIG. 1.

FIG. 10 is an illustration of the bite capture apparatus of FIG. 9 afterthe motion capture structure has captured the relative motion from theopposing dentition of the patient.

FIG. 11 illustrates an exemplary architecture of the program modules andprogram data of the design system of FIG. 1.

FIG. 12 is a flow chart illustrating an example method of fabricatingthe dental restoration using the interference model data of FIG. 1.

FIG. 13 is a flow chart illustrating an example method of fabricatingthe interference model using the interference model data of FIG. 1.

FIG. 14 is a cross-section illustration of an example interference modelof FIG. 1, including an interference surface.

FIG. 15 is a schematic diagram of an embodiment of the interferencemodel of FIG. 1.

FIG. 16 is an illustration of an example embodiment of the interferencemodel of FIG. 1 joined with a dental model.

FIG. 17 is an illustration of another example embodiment of theinterference model of FIG. 1 joined with a dental model.

FIG. 18 is an illustration of the dental model of FIG. 16 with the bitecapture apparatus of FIG. 9.

FIG. 19 is a flow chart illustrating an example method of fabricatingthe dental restoration using the interference model of FIG. 1.

FIG. 20 is a flow chart illustrating an example method of designing thedental restoration data using the interference model data of FIG. 1.

FIG. 21 is an illustration of a cross-sectional view of the interferencemodel data and the dental restoration data of FIG. 1.

FIG. 22 is an illustration of a cross-sectional view of the dentalrestoration data of FIG. 1 with an example embodiment of a color map onthe exterior surface.

FIG. 23 is a schematic block diagram illustrating an example of a systemfor simulating incisal guide paths to fabricate a provisionalrestoration.

FIG. 24 illustrates an exemplary architecture of the program modules andthe program data of the provisional design system of FIG. 23.

FIG. 25 is a flow chart illustrating an example method of using thesystem of FIG. 23 to fabricate and install the provisional restoration.

FIG. 26 is a flow chart illustrating another example method of using thesystem of FIG. 23 to fabricate and install the provisional restoration.

FIG. 27 is a flow chart illustrating an example method of using thesystem of FIG. 23 to fabricate a dental restoration based on theprovisional restoration.

FIG. 28 is a cross-sectional illustration of the anterior dentition ofthe patient.

FIG. 29 is an illustration of an example of an embodiment of theprovisional restoration mold of FIG. 23.

FIG. 30 is an illustration of an alternative embodiment of theprovisional restoration mold of FIG. 23.

FIG. 31 is a cross-sectional illustration of a provisional restorationmold of FIG. 23 being used to form a provisional restoration on arestoration site R.

FIG. 32 is a cross-sectional illustration of an articulator being usedwith an incisal guide model of FIG. 23.

DETAILED DESCRIPTION

Various embodiments will be described in detail with reference to thedrawings, wherein like reference numerals represent like parts andassemblies throughout the several views. Reference to variousembodiments does not limit the scope of the claims attached hereto.Additionally, any examples set forth in this specification are notintended to be limiting and merely set forth some of the many possibleembodiments for the appended claims.

The present disclosure relates to a system for fabricating dentalrestorations. The dental restoration is configured to temporarily orpermanently replace part or all of one or more of a patient's teeth. Insome embodiments, the dental restorations are fabricated to avoidinterfering with the opposing dentition. In some embodiments, relativemotion data is used to construct an interference model representative ofthe position of the opposing dentition in multiple bite locations. Insome embodiments, a mold is fabricated based on an incisal guide plane.In some embodiments, the mold is used to fabricate the restoration. Insome embodiments, the incisal guide plane is generated from motion data.In other embodiments, the incisal guide plane is generated from animpression of the dentition of a patient.

FIG. 1 is a schematic block diagram illustrating an example of a system100 for simulating occlusal interference using a functional bite map tofabricate a dental restoration 134. In this example, the system 100includes a dental office 102 and a dental lab 114.

The example dental office 102 includes a dental impression station 104,a motion capture station 106, and a restoration installation station136. Although shown as a single dental office in this figure, in someembodiments, the dental office 102 comprises multiple dental offices.For example, in some embodiments, one or both of the dental impressionstation 104 and the motion capture station 106 are in a different dentaloffice than the restoration installation station 136. Further, in someembodiments, one or more of the dental impression station 104, themotion capture station 106, and the restoration installation station 136are not in a dental office.

The example dental impression station 104 generates a dental impression108 of the dentition of the patient P. The dental impression 108 is ageometric representation of the dentition of the patient P. In someembodiments, the dental impression 108 is a physical impression capturedusing an impression material, such as sodium alginate, or vinylpolysiloxane. In other embodiments, other impression materials are usedas well.

In some embodiments, the dental impression 108 is a digital impression.In some embodiments, the digital impression is represented by one ormore of a point cloud, a polygonal mesh, a parametric model, or voxeldata. In some embodiments, the digital impression is generated directlyfrom the dentition of the patient P, using for example an intraoralscanner. Example intraoral scanners include the TRIOS Intra Oral DigitalScanner, the Lava Chairside Oral Scanner C.O.S., the Cadent iTero, theCerec AC, the Cyrtina IntraOral Scanner, and the Lythos DigitalImpression System from Ormco. In other embodiments, a digital impressionis captured using other imaging technologies, such as computedtomography (CT) or magnetic resonance imaging (MRI). In yet otherembodiments, the digital impression is generated from a physicalimpression by scanning the impression or plaster model of the dentitionof the patient P created from the physical impression. Examples oftechnologies for scanning a physical impression or model include threedimensional laser scanners and computed tomography (CT) scanners. In yetother embodiments, digital impressions are created using othertechnologies.

The motion capture station 106 captures a representation of the movementof the dental arches relative to each other. In some embodiments, themotion capture station generates at least one of a functional bite map110 and motion data 112.

In some embodiments, the functional bite map 110 is a physical apparatuscontaining indentations that form a path that corresponds to themovement of the dental arches of the patient relative to each other. Forexample, in some embodiments, the functional bite map 110 is formed inone or more sheets of a bite registration material. In some embodiments,the patient P bites into the bite registration material. In someembodiments, after the patient P bites into the bite registrationmaterial, the patient P is instructed to move between various bitepositions, such as such as centric, excursive, left lateral, and rightlateral. In other embodiments, the functional bite map 110 is formedfrom multiple sheets of bite registration material that are eachcaptured in a different bite position. In some embodiments, the biteregistration material is formed from wax, alginate, vinyl polysiloxane,or combinations thereof. In some embodiments, the bite registrationmaterial is formed from wax infused with a powdered metal, such asaluminum or copper. Some example bite registration materials includeTHEMACRYL® thermoplastic material from Airway Technologies, LLC ofCarrollton, Tex.; vinyl polysiloxane putty such as FLEXITIME® impressionmaterial from Heraeus Kulzer of South Bend, Ind.; FUTAR® D biteregistration material from Roydent Dental Products of Johnson City,Tex.; ESPE™ EXPRESS™ impression material from 3M of St. Paul, Minn. Inother embodiments, other materials are used to capture the bite record.

In other embodiments, the motion capture station 106 generates motiondata 112 representing the movement of the arches relative to oneanother. In some embodiments, the motion capture station 106 generatesthe motion data 112 from optical measurements of the dental arches thatare captured while the dentition of the patient is moved. In someembodiments, the optical measurements are extracted from image or videodata recorded while the dentition of the patient is moved. Additionally,in some embodiments, the optical measurements are captured indirectly.For example, in some embodiments, the optical measurements are extractedfrom images or video data of a one or more devices that are secured to aportion of the dentition of the patient. In other embodiments, themotion data 112 is generated using other processes. Further, in someembodiments, the motion data 112 includes transformation matrices thatrepresent the position and orientation of the dental arches. Otherembodiments of the motion data 112 are possible as well.

The example dental lab 114 includes a 3D scanner 116, design system 118,rapid fabrication machine 126, and a restoration fabrication station132. Although shown as a single dental lab in this figure, in someembodiments, the dental lab 114 comprises multiple dental labs. Forexample, in some embodiments, the 3D scanner 116 is in a differentdental lab than one or more of the other components shown in the dentallab 114. Further, in some embodiments, one or more of the componentsshown in the dental lab 114 are not in a dental lab. For example, insome embodiments, one or more of the 3D scanner 116, design system 118,rapid fabrication machine 126, and restoration fabrication station 132are in the dental office 102. Additionally, some embodiments of thesystem 100 do not include all of the components shown in the dental lab114.

The example 3D scanner 116 is a device configured to create athree-dimensional digital representation of one or both of the dentalimpression 108 and the functional bite map 110. In some embodiments, the3D scanner 116 generates a point cloud, a polygonal mesh, a parametricmodel, or voxel data representing the dental impression 108 or thefunctional bite map 110. In some embodiments, the 3D scanner 116generates the digital dental model 120 or the functional bite map data121. In some embodiments, the 3D scanner 116 comprises a laser scanner,a touch probe, or an industrial CT scanner. Yet other embodiments of the3D scanner 116 are possible as well. Further, some embodiments of thesystem 100 do not include the 3D scanner 116. For example, in someembodiments of the system 100 where the dental impression station 104generates a digital dental impression and the motion capture station 106generates motion data 112, the 3D scanner 116 is not included.

The design system 118 is a system that is configured to generate one orboth of the interference model data 122 and the dental restoration data124. In some embodiments, the interference model data 122 isthree-dimensional digital data that represents the interference model128 and is in a format suitable for fabrication using the rapidfabrication machine 126. Similarly, in some embodiments, the dentalrestoration data 124 is three-dimensional digital data that representsthe dental restoration component 130 and is in a format suitable forfabrication using the rapid fabrication machine 126.

In some embodiments, the design system 118 comprises a computing deviceincluding user input devices. In some embodiments, the design system 118includes computer-aided-design (CAD) software that generates a graphicaldisplay of one or both of the interference model data 122 and the dentalrestoration data 124 and allows an operator to interact with andmanipulate one or both of the interference model data 122 and the dentalrestoration data 124. In some embodiments, the design system 118comprises digital tools that mimic the tools used by a laboratorytechnician to physically design a dental restoration. In some otherembodiments, the design system 118 comprises a server that partially orfully automates the generation of designs of one or both of theinterference model data 122 and the dental restoration data 124.

In some embodiments, the rapid fabrication machine 126 comprises one ormore three-dimensional printers, such as the ProJet line of printersfrom 3D Systems, Inc. of Rock Hill, S.C. Another example of the rapidfabrication machine 126 is stereolithography equipment. Yet anotherexample of the rapid fabrication machine 126 is a milling device, suchas a computer numerically controlled (CNC) milling device. In someembodiments, the rapid fabrication machine 126 is configured to receivefiles in the STL format. Other embodiments of the rapid fabricationmachine 126 are possible as well.

In some embodiments, the rapid fabrication machine 126 is configured touse the interference model data 122 to fabricate the interference model128. In some embodiments, the interference model 128 is a physicalstructure comprising a surface configured to oppose a dental restoration134. In some embodiments, the interference model 128 is formed as acomposite of the location of the dental arch opposite the dentalrestoration 134 along the various bite paths recorded by the functionalbite map 110 or the motion data 112. In some embodiments, theinterference model 128 comprises one or more retention structures thatare configured to couple to a dental model and properly position theinterference model 128 relative to the dental restoration 134. However,in some other embodiments, the restoration fabrication station 132 doesnot fabricate the interference model 128. For example, in someembodiments, a digital interference model is used by the design system118 and it is not fabricated into a physical apparatus.

Additionally, in some embodiments, the rapid fabrication machine 126 isconfigured to use the dental restoration data 124 to fabricate thedental restoration component 130. In some embodiments, the dentalrestoration component 130 is a physical component that is configured tobe used as part or all of the dental restoration 134. For example, insome embodiments, the dental restoration component is milled fromzirconium or another material that is used directly as a dentalrestoration. In other embodiments, the dental restoration component 130is a mold formed from wax or another material and is configured to beused indirectly (e.g., through a lost was casting or ceramic pressingprocess) to fabricate the dental restoration 134. For example, in someembodiments, the dental restoration 134 is formed using traditionaltechniques (e.g., stacked porcelain or wax-up) using a dental model thatincludes the interference model 128.

In some embodiments, the restoration fabrication station 132 operates tofabricate a dental restoration 134 for the patient P. In someembodiments, the restoration fabrication station 132 uses theinterference model 128 or the dental restoration component 130 producedby the rapid fabrication machine 126. In some embodiments, the dentalrestoration 134 is a filling, partial crown, full crown, veneer, orbridge. Other embodiments of the dental restoration 134 are possible aswell. In some embodiments, the dental restoration 134 is formed a froman acrylic, ceramic, or metallic material. In some embodiments, thedental impression 108 is used in the fabrication of the dentalrestoration 134. In some embodiments, the dental impression 108 is usedto form a plaster model of the dentition of the patient P. Additionally,in some embodiments, a model of the dentition of the patient P isgenerated by the rapid fabrication machine 126. In some embodiments, therestoration fabrication station 132 comprises equipment and process toperform some or all of the techniques used in traditional dentallaboratories to generate dental restorations. Other embodiments of therestoration fabrication station 132 are possible as well.

In some embodiments, the dental restoration 134 is seated in the mouthof the patient P in the restoration installation station 136 by adentist D. In some embodiments, the dentist D confirms that the occlusalsurface of the dental restoration 134 is properly defined by instructingthe patient P to engage in various bites.

Additionally, in some embodiments, the dental office 102 is connected tothe dental lab 114 by network 138.

The network 138 is an electronic communication network that facilitatescommunication between the dental office 102 and the dental lab 114. Anelectronic communication network is a set of computing devices and linksbetween the computing devices. The computing devices in the network usethe links to enable communication among the computing devices in thenetwork. The network 138 can include routers, switches, mobile accesspoints, bridges, hubs, intrusion detection devices, storage devices,standalone server devices, blade server devices, sensors, desktopcomputers, firewall devices, laptop computers, handheld computers,mobile telephones, and other types of computing devices.

In various embodiments, the network 138 includes various types of links.For example, the network 138 can include one or both of wired andwireless links, including Bluetooth, ultra-wideband (UWB), 802.11,ZigBee, and other types of wireless links. Furthermore, in variousembodiments, the network 138 is implemented at various scales. Forexample, the network 138 can be implemented as one or more local areanetworks (LANs), metropolitan area networks, subnets, wide area networks(such as the Internet), or can be implemented at another scale.

FIG. 2 illustrates an exemplary architecture of a computing device 160that can be used to implement aspects of the present disclosure,including any of the plurality of computing devices described herein,such as a computing device of the dental impression station 104, motioncapture station 106, 3D scanner 116, design system 118, rapidfabrication machine 126, restoration fabrication station 132, or anyother computing devices that may be utilized in the various possibleembodiments.

The computing device illustrated in FIG. 2 can be used to execute theoperating system, application programs, and software modules (includingthe software engines) described herein.

The computing device 170 includes, in some embodiments, at least oneprocessing device 180, such as a central processing unit (CPU). Avariety of processing devices are available from a variety ofmanufacturers, for example, Intel or Advanced Micro Devices. In thisexample, the computing device 170 also includes a system memory 182, anda system bus 184 that couples various system components including thesystem memory 182 to the processing device 180. The system bus 184 isone of any number of types of bus structures including a memory bus, ormemory controller; a peripheral bus; and a local bus using any of avariety of bus architectures.

Examples of computing devices suitable for the computing device 170include a desktop computer, a laptop computer, a tablet computer, amobile computing device (such as a smart phone, an iPod® or iPad® mobiledigital device, or other mobile devices), or other devices configured toprocess digital instructions.

The system memory 182 includes read only memory 186 and random accessmemory 188. A basic input/output system 190 containing the basicroutines that act to transfer information within computing device 170,such as during start up, is typically stored in the read only memory186.

The computing device 170 also includes a secondary storage device 192 insome embodiments, such as a hard disk drive, for storing digital data.The secondary storage device 192 is connected to the system bus 184 by asecondary storage interface 194. The secondary storage devices 192 andtheir associated computer readable media provide nonvolatile storage ofcomputer readable instructions (including application programs andprogram modules), data structures, and other data for the computingdevice 170.

Although the exemplary environment described herein employs a hard diskdrive as a secondary storage device, other types of computer readablestorage media are used in other embodiments. Examples of these othertypes of computer readable storage media include magnetic cassettes,flash memory cards, digital video disks, Bernoulli cartridges, compactdisc read only memories, digital versatile disk read only memories,random access memories, or read only memories. Some embodiments includenon-transitory media. Additionally, such computer readable storage mediacan include local storage or cloud-based storage.

A number of program modules can be stored in secondary storage device192 or system memory 182, including an operating system 196, one or moreapplication programs 198, other program modules 200 (such as thesoftware engines described herein), and program data 202. The computingdevice 170 can utilize any suitable operating system, such as MicrosoftWindows™, Google Chrome™ OS, Apple OS, Unix, or Linux and variants andany other operating system suitable for a computing device. Otherexamples can include Microsoft, Google, or Apple operating systems, orany other suitable operating system used in tablet computing devices.

In some embodiments, a user provides inputs to the computing device 170through one or more input devices 204. Examples of input devices 204include a keyboard 206, mouse 208, microphone 210, and touch sensor 212(such as a touchpad or touch sensitive display). Other embodimentsinclude other input devices 204. The input devices are often connectedto the processing device 180 through an input/output interface 214 thatis coupled to the system bus 184. These input devices 204 can beconnected by any number of input/output interfaces, such as a parallelport, serial port, game port, or a universal serial bus. Wirelesscommunication between input devices and the interface 214 is possible aswell, and includes infrared, BLUETOOTH® wireless technology,802.11a/b/g/n, cellular, ultra-wideband (UWB), ZigBee, or other radiofrequency communication systems in some possible embodiments.

In this example embodiment, a display device 216, such as a monitor,liquid crystal display device, projector, or touch sensitive displaydevice, is also connected to the system bus 184 via an interface, suchas a video adapter 218. In addition to the display device 216, thecomputing device 170 can include various other peripheral devices (notshown), such as speakers or a printer.

When used in a local area networking environment or a wide areanetworking environment (such as the Internet), the computing device 170is typically connected to the network through a network interface 220,such as an Ethernet interface. Other possible embodiments use othercommunication devices. For example, some embodiments of the computingdevice 170 include a modem for communicating across the network.

The computing device 170 typically includes at least some form ofcomputer readable media. Computer readable media includes any availablemedia that can be accessed by the computing device 170. By way ofexample, computer readable media include computer readable storage mediaand computer readable communication media.

Computer readable storage media includes volatile and nonvolatile,removable and non-removable media implemented in any device configuredto store information such as computer readable instructions, datastructures, program modules or other data. Computer readable storagemedia includes, but is not limited to, random access memory, read onlymemory, electrically erasable programmable read only memory, flashmemory or other memory technology, compact disc read only memory,digital versatile disks or other optical storage, magnetic cassettes,magnetic tape, magnetic disk storage or other magnetic storage devices,or any other medium that can be used to store the desired informationand that can be accessed by the computing device 170.

Computer readable communication media typically embodies computerreadable instructions, data structures, program modules or other data ina modulated data signal such as a carrier wave or other transportmechanism and includes any information delivery media. The term“modulated data signal” refers to a signal that has one or more of itscharacteristics set or changed in such a manner as to encode informationin the signal. By way of example, computer readable communication mediaincludes wired media such as a wired network or direct-wired connection,and wireless media such as acoustic, radio frequency, infrared, andother wireless media. Combinations of any of the above are also includedwithin the scope of computer readable media.

The computing device illustrated in FIG. 2 is also an example ofprogrammable electronics, which may include one or more such computingdevices, and when multiple computing devices are included, suchcomputing devices can be coupled together with a suitable datacommunication network so as to collectively perform the variousfunctions, methods, or operations disclosed herein.

FIG. 3 is a flow chart illustrating an example method 250 of capturing adental impression. In some embodiments, the method 250 is performed atthe dental impression station 104. In this example, the method 250includes operations 252, 254, 256, and 258.

At operation 252, the dentition of the patient P is captured. Asdescribed above with respect to FIG. 1, in some embodiments, thedentition is captured using a physical impression material and in otherembodiments, the dentition is captured using a digital impressionsystem.

At operation 254, the bite record of the patient P is captured. In someembodiments, the bite record comprises information about contact betweenthe upper dentition and lower dentition of the patient. In someembodiments, the bite record is captured in one or more of followingpositions: centric occlusion, centric relation, and various excursivebite positions. In some embodiments, this operation is not performed andthe bite record is not captured.

In some embodiments, the bite record is captured using a biteregistration material such as bite registration wax or polysiloxane. Abite registration material captures the relationship between the upperand lower dentition of the patient P as indents when the patient P bitesinto the material.

At operation 256, the restoration prescription is entered. In someembodiments, the restoration prescription comprises information aboutthe type of restoration the doctor D is prescribing for the patient P.In some embodiments, the restoration prescription includes the identityof the tooth or teeth that are being restored, the desired restorationmaterial/s, the desired type of restoration, and additional instructionsfor fabricating the restoration. In some embodiments, the restorationprescription is entered into a computing device where it is stored. Inother embodiments, the restoration prescription is entered into a paperform. Other embodiments are possible as well.

At operation 258, the dental impression 108 is transmitted. In someembodiments, the dental impression 108 is transmitted to the dental lab114. In some embodiments, the bite record captured in operation 254 andthe restoration prescription entered in operation 256 are transmittedwith the dental impression 108. In some embodiments, the dentalimpression 108 is transmitted across the network 138 as a digitalimpression. In other embodiments, the dental impression 108 istransmitted as a physical dental impression or dental model.

FIG. 4 is an example process 280 performed at some embodiments of themotion capture station 106.

At operation 282, the bite capture apparatus is secured to the dentalarch that includes the tooth or teeth that are being restored. In someembodiments, the bite capture apparatus is secured so that it issubstantially immovable relative the dental arch that includes the toothor teeth that are being restored. In some embodiments, the bite captureapparatus includes a first surface that is configured to secure the bitecapture apparatus to a dental arch, and a second surface that isconfigured to record the relative movement of the opposite arch.

At operation 284, the patient's jaw is closed into a first biteposition. For example, in some embodiments, the patient's jaw is closedinto a centric bite. In some embodiments, the patient is instructed tobite into the bite capture apparatus. In other embodiments, the dentistor another caregiver may physically guide the patient's jaw into thebite position.

At operation 286, it is determined whether there are more bite positionsto capture. For example, in some embodiments, the patient's bite will becaptured in some or all of the following positions: centric, excursive,left lateral, and right lateral. If there are more bite positions tocapture, the process 280 continues to operation 288, where the patient'sbite is moved into the next bite position. In some embodiments, thepatient continues to apply bite force on the bite capture apparatus asthe bite is moved to the next bite position. In this manner, the bitecapture apparatus record the relative location of the opposing dentitionthroughout the full bite path. If there are not any more bite positionsto capture, the process 280 continues to operation 290.

At operation 290, the bite capture apparatus is removed from thedentition of the patient. In some embodiments, at this point, the bitecapture apparatus will have recorded the relative location of theopposing dentition in all bite positions and all bite paths betweenthose bite positions.

At operation 292, the functional bite map 110 is transmitted. In someembodiments, the functional bite map 110 is transmitted to the dentallab 114. In some embodiments, the functional bite map 110 comprises theentire bite capture apparatus. In other embodiments, the functional bitemap comprises only the portion (e.g., the motion capture layer) of thebite capture apparatus that includes the indents corresponding to therelative locations of the patient P's dentition in various bitepositions and along the paths between those positions. In someembodiments, the functional bite map 110 is transmitted across thenetwork 138 after being digitized using a three-dimensional scanner,such as an impression scanner. In other embodiments, the functional bitemap 110 is transmitted as a physical dental impression or dental model.

FIG. 5 is an example embodiment of a bite capture apparatus 340 forcapturing a functional bite map 110. In some embodiments, the bitecapture apparatus 340 is used at the motion capture station 106. In someembodiments, the bite capture apparatus includes a securing layer 342, aseparating layer 344, and a motion capture layer 346. In someembodiments, the bite capture apparatus 340 is configured to be placedin the patient's mouth and bitten into by the patient P.

The securing layer 342 is an apparatus and is configured to secure thebite capture apparatus 340 to the dentition of the patient. In someembodiments, the securing layer 342 comprises a layer of material. Inother embodiments, the securing layer 342 comprises one or mechanicaldevices configured to secure the bite capture apparatus 340 to one ormore of the teeth in patient's dentition. In some embodiments, thesecuring layer 342 is configured to be secured to the maxillary arch. Inother embodiments, the bite capture layer is configured to be securedmandibular arch. In other embodiments, the securing layer 342 isconfigured to be secured to either arch.

In some embodiments, the securing layer 342 is formed from an impressionmaterial, such as vinyl polysiloxane, wax, or other materials. Forexample, in some embodiments, the securing layer 342 is formed from athixotropic vinyl polysiloxane, such as BLU-MOUSSE® from Parkell Inc. inEdgewood, N.Y. In some embodiments, the securing layer 342 is warmed andthe pressed into the dentition of the patient until it cools and hardensor becomes substantially rigid. In some embodiments, the securing layer342 is very thin after it is secured to the patient's dentition. Forexample, in some embodiments, the securing layer 342 is less than fiftymicrometers thick. In yet other embodiments, at least some points on thedentition create holes in the securing layer 342. In some embodiments,this advantageously minimizes the amount of interference to thepatient's bite that is caused by the presence of the securing layer 342.

The separating layer 344 is configured to separate the securing layer342 from the motion capture layer 346. In some embodiments, theseparating layer 344 is formed from a thin sheet of foil or plastic. Forexample, in some embodiments, the separating layer 344 is between 5-50micrometers thick.

The motion capture layer 346 is a layer of material configured tocapture the relative motion of the patient's teeth. In some embodiments,the motion capture layer 346 captures indentations created by thepatient's teeth on the arch opposing the teeth the bite captureapparatus 340 is secured to. In some embodiments, the motion capturelayer 346 is formed from wax that remains pliable at room temperature.In other embodiments, the motion capture layer is formed from othermaterials.

FIG. 6 is an illustration of an embodiment of the bite capture apparatus340 being used to capture bite motion information of a patient P. Theupper arch U and the lower arch of the patient P are shown.

In this example, the securing layer 342 is secured to the upper arch Uand the motion capture layer 346 is configured to capture indentationsmade by the lower arch L. In this manner, if the patient P moves betweendifferent bite positions, the motion capture layer 346 will includeindentations that represent the location of the lower arch L relative tothe upper arch U in the various bite positions and on the bite pathsbetween those positions.

FIG. 7 is an illustration of an embodiment of the bite capture apparatus340 after the securing layer 342 has formed to the patient P'sdentition. In this example, the securing layer 342 includes securingindents 370. In some embodiments, the securing indents 370 correspond tothe positions and shapes of the teeth the bite capture apparatus 340 isconfigured to be secured to. In some embodiments, the securing indents370 are formed when the securing layer 342 is pressed against the teethof the patient P. In some embodiments, the securing layer 342 is softand pliable at the time it is pressed against the patient P's teeth.Further, in some embodiments, the securing layer 342 cures or hardensafter a time period.

FIG. 8 is an illustration of an embodiment of the bite capture apparatus340 after the motion capture layer 346 has captured the relative motionfrom the patient P's dentition. In this example, the motion capturelayer 346 includes motion indents 410. In some embodiments, the motionindents 410 correspond to the relative positions of the teeth oppositeof the securing layer 342. In some embodiments, the motion indents 410are formed when the patient P's jaw is positioned and moved betweenvarious bite positions. In some embodiments, the motion indents 410represent a union of the teeth in multiple bite positions. In someembodiments, the motion capture layer 346 remains soft and pliablethroughout the time the patient is wearing the bite capture apparatus340.

FIG. 9 is another example embodiment of a bite capture apparatus 420 forcapturing a functional bite map 110. In some embodiments, the bitecapture apparatus 420 is used at the motion capture station 106. In someembodiments, the bite capture apparatus 420 includes a motion capturestructure 422 and a securing structure 424. The bite capture apparatus420 is configured to be secured to a restoration site R of the patient.

The motion capture structure 422 is a structure configured to capturethe relative motion of the patient's teeth. In some embodiments, themotion capture structure 422 captures indentations created by thepatient's teeth on the arch opposing the restoration site the bitecapture apparatus 420 is secured to. In some embodiments, the motioncapture layer 346 is formed from a pliable wax. In other embodiments,the motion capture layer 346 is formed from a combination of wax and ametal, such as copper or aluminum. In other embodiments, the motioncapture layer is formed from other materials.

In some embodiments, the motion capture structure 422 has a bulbous orspherical shape. In some embodiments, the motion capture structure 422has a shape that is similar to a large, bulbous tooth. In otherembodiments, the motion capture structure 422 has another shape.

The securing structure 424 is a structure that operates to secure thebite capture apparatus 420 to the restoration site R. In someembodiments, the securing structure 424 is a cavity that is large enoughto fit over the restoration site R. In some embodiments, the securingstructure 424 is configured to be secured to the restoration site R byfilling the securing structure 424 with a quick-set vinyl polysiloxanematerial and then placing the bite capture apparatus 420 over therestoration site R.

In some embodiments, the motion capture structure 422 is similar to apre-fabricated crown, such as an anodized crown, except that it is morebulbous and lacks dental anatomy.

FIG. 10 is an illustration of the bite capture apparatus 420 after themotion capture structure 422 has captured the relative motion from theopposing dentition O of the patient P. The motion capture structure 422now includes indents 430 and 432 that were created by the opposingdentition O as it moved through various bite paths. Also shown are thearrows LL and LR. The arrow LL indicates the direction in which theopposing dentition O moves along the lateral left bite path. When theopposing dentition O moves in the direction of the arrow LR, it carvesout part of the indent 432. The arrow LR indicates the direction inwhich the opposing dentition O moves along the lateral right bite path.When the opposing dentition O moves in the direction of the arrow LR, itcarves out part of the indent 430.

In some embodiments, after the motion capture structure 422 has capturedindents representing some or all of the bite paths and positions of thepatient P, the bite capture apparatus 420 is removed from therestoration site R so that it can be transmitted to the dental lab 114.In some embodiments, the bite capture apparatus 420 is transmitted tothe dental lab 114 by being physically delivered. Once transmitted tothe dental lab 114, in some embodiments, the bite capture apparatus 420is placed on a plaster model of restoration site R and scanned by the 3Dscanner 116.

In other embodiments, after the motion capture structure 422 hascaptured indents representing some or all of the bite paths andpositions of the patient P, the bite capture apparatus 420 is scannedusing a digital impressioning system and then transmitted digitally tothe dental lab 114. Other embodiments are possible as well.

FIG. 11 illustrates an exemplary architecture of the program modules 200and program data 202 of the design system 118. The program modules 200include a plurality of modules that, when executed by the processingdevice 180 (shown in FIG. 2), perform one or more operations of thedesign system 118. The modules include an interference modeling engine450 and a restoration design engine 452. In some embodiments, theprogram modules 200 includes more, fewer, or different modules thanthose shown in FIG. 11.

The program data 202 is stored in a data storage device, such as thememory 182 or the secondary storage device 192 (shown in FIG. 2). Insome embodiments, program data 202 includes impression data 454, bitemovement data 456, the interference model data 122, and the dentalrestoration data 124. In some embodiments, the program data 202 includemore, fewer, or different types of data than the data shown in FIG. 9.

In some embodiments, the data stored in program data 202 can berepresented in one or more files having any format usable by a computer.Examples include text files formatted according to a markup language andhaving data items and tags to instruct computer programs and processeshow to use and present the data item. Examples of such formats includehtml, xml, and xhtml, although other formats for text files can be used.Additionally, the data can be represented using formats other than thoseconforming to a markup language.

The interference modeling engine 450 operates to generate theinterference model data 122. In some embodiments, the interferencemodeling engine 450 uses the impression data 454 and the bite movementdata 456 to generate the interference model data 122.

The restoration design engine 452 operates to generate the dentalrestoration data 124. In some embodiments, the restoration design engine452 uses the impression data 454 and the interference model data 122 togenerate the dental restoration data 124.

FIG. 12 is a flow chart illustrating an example method 490 offabricating the dental restoration 134 using the interference model data122. In some embodiments, the method 490 is performed by theinterference modeling engine 450 and the restoration design engine 452using a processor (such as processing device 180, shown in FIG. 2). Inthis example, the method 490 includes operations 492, 494, and 496.

At operation 492, the digital dental model 120 and movement informationare received. In some embodiments, the digital dental model 120 isgenerated from a dental impression 108 that is transmitted digitally bythe dental impression station 104 and is converted into the digitaldental model 120.

In other embodiments, the digital model is generated from a physicalimpression. In some of these embodiments, the dental impression 108 isscanned by the 3D scanner 116 to create the digital dental model 120. Inother of these embodiments, a plaster model is formed from the physicalimpression and then the plaster model is scanned by the 3D scanner 116to create the digital dental model 120. Other embodiments are possibleas well.

In some embodiments, the movement information is received as motion data112 directly from the motion capture station 106. In other embodiments,the movement information is received as functional bite map data 121that is generated by scanning the functional bite map 110 using the 3Dscanner 116.

At operation 494, the interference model data 122 is generated from thedental impression and the movement information. In some embodiments, theinterference model data 122 represents a polygonal surface. In otherembodiments, the interference model data represents a polygonal model.In some embodiments, the interference model data 122 comprises a surfaceof the functional bite map data 121. In other embodiments, theinterference model data 122 is generated by sweeping a portion of thedigital dental model 120 along the movement path recorded in the motiondata 112. In some embodiments, a portion of the dental arch that opposesthe site for the dental restoration 134 is swept along the movementpaths. In other embodiments, the interference model data 122 isgenerated by using Boolean operations to generate a model that therepresents the union of the opposing dentition in multiple bitelocations.

At operation 496, the restoration is designed using the digital dentalmodel 120 and the interference model. In some embodiments, theinterference model is visualized in relation to the restoration site. Insome embodiments, an operator utilizes a user interface to design thedental restoration data 124 to avoid contact with the interferencemodel. In other embodiments, the dental restoration data 124 is designedautomatically by the restoration design engine to avoid contact with adigital interference model.

FIG. 13 is a flow chart illustrating an example method 530 offabricating the interference model 128 using the interference model data122. In some embodiments, the method 530 is performed by the restorationdesign engine 452 using a processor (such as processing device 180,shown in FIG. 2). In this example, the method 530 includes operations532, 534, 536, 538, 540, 542, 544, 546, 548, and 550.

At operation 532 it is determined whether a functional bite map 110 ormotion data 112 is provided. If a functional bite map 110 is provided,the method 530 continues to operation 534. If not, the method 530continues to operation 536.

At operation 534, a digital surface is generated from the functionalbite map 110.

At operation 536, a digital model of the opposing dentition isgenerated. At operation 538, the digital model of the opposing dentitionis swept along the movement path/s recorded in the motion data 112.

At operation 540, an interference surface opposing the restoration siteis extracted. In some embodiments, the interference surface is extractedfrom the digital surface generated from the functional bite map 110 atoperation 534. In other embodiments, the interference surface isextracted from the sweep of the digital model of the opposing dentitionat operation 538. In some embodiments, only a portion of theinterference surface is extracted. For example, in some embodiments, aportion of the interference surface directly opposite the restorationsite is extracted. In other embodiments, a larger portion of theocclusal surface is extracted. For example, in some embodiments, aportion of the interference surface opposing the teeth adjacent to therestoration site is extracted as well.

At operation 542, it is determined whether a physical interference modelwill be Fabricated. If so, the method 530 continues to operation 544. Ifnot, the method 530 ends and the interference surface extracted atoperation 540 is ready for use in digital dental design.

At operation 544, a retention structure is built. The retentionstructure operates to align the interference surface to a physical modelof the patient P's dentition. In some embodiments, the retentionstructure is configured to secured the interference surface to thepatient P's dentition. In other embodiments, the retention structure isconfigured to align the interference surface without securing it. Insome embodiments, the retention structure is a band, clasp, or surfacethat matches the contour of the adjacent dentition. In otherembodiments, the retention structure is a male or female connector thatis configured to mate with an opposite connector that is added to thephysical model of the patient P's dentition. Other embodiments arepossible as well.

At operation 546, the retention structure is joined to the interferencestructure to form an integral digital interference model.

At operation 548, interferences with the adjacent dentition are removedfrom the interference surface. In some embodiments, this ensures thatinterferences with the adjacent teeth do not prevent the interferencesurface from being properly aligned relative to the restoration site.

At operation 550, the interference model data is transmitted to therapid fabrication machine 126 for fabrication.

FIG. 14 is a cross-section illustration of an example interference model128, including an interference surface 580. Also shown is therestoration site R and the opposing dentition O.

The interference surface 580 is a surface that is operates to indicatewhere a dental restoration would interfere with the opposing dentition Oin at least one of the bite positions or along one of the paths betweenbite positions. In the example shown in FIG. 14, the interferencesurface 580 corresponds to the inverse of the indents 430 and 432 in thebite capture apparatus 420 shown in FIG. 10.

In some embodiments, the cross-section of the interference surface 580is larger than the cross-section of the opposing dentition O because theinterference surface 580 represents the union of the opposing dentitionO in multiple bite locations. In some embodiments, the interferencemodel 128 is used to design a dental restoration 134 for the restorationsite R. For example, in some embodiments, the dental restoration 134 isdesigned so that it does not contact or interfere with the interferencesurface 580. In this manner, the dental restoration 134 will not contactor interfere with the opposing dentition O in any of the bite positionsthat were used to generate the interference surface 580.

FIG. 15 is a schematic diagram of an embodiment of the interferencemodel 128. In this example, the interference model 128 includes theinterference surface 580 and the retention structure 610. In thisexample, the interference surface 580 occupies only a portion of thedental arch. In some embodiments, the retention structure 610 isgenerated to follow the dental arch of the opposing dentition O. In someembodiments, the retention structure 610 comprises at least a portion ofthe opposing dentition O.

FIG. 16 is an illustration of an example embodiment of the interferencemodel 128 joined with a dental model 640. The interference model 128includes the interference surface 580, and the opposing dentitionsurface 646. The dental model 640 includes a model 642 of therestoration site R, and a model 644 of the adjacent dentition. Alsoshown are retention structures 648 a-b. The retention structures 648 a-bare formed from lower pins 652 a-b and upper pins 650 a-b. The lowerpins 652 a-b extend from the dental model 640 and are configured to matewith the upper pins 650 a-b, which extend from the interference model128. When the lower pins 652 a-b are mated with the upper pins 650 a-b,the interference model 128 is properly aligned with the dental model640. Some embodiments, include more or fewer of the retention structures648 a-b. Additionally, some embodiments, include different types ofretention structures.

FIG. 17 is an illustration of another example embodiment of theinterference model 128 joined with a dental model 640. The interferencemodel 128 includes the interference surface 580 and retention clips 680a-b. The retention clips 680 a-b are configured to mate with theocclusal surface of the model 644 of the adjacent dentition. When theretention clips 680 a-b are mated with the model 644 of the adjacentdentition, the interference model 128 is properly aligned with thedental model 640. Some embodiments, include more or fewer of theretention clips 680 a-b.

FIG. 18 is an illustration of the dental model 640. In thisillustration, the bite capture apparatus 420 is also shown. The bitecapture apparatus 420 is disposed on the model 642 of the restorationsite. In some embodiments, the interference surface 580 (shown, forexample, in FIGS. 16-17) fits snugly over the surface of the bitecapture apparatus 420. In fact, in some embodiments, the bite captureapparatus 420 is disposed on the model 642 of the restoration site andscanned by the 3D scanner 116 as part of the process of generating theinterference surface 580.

FIG. 19 is a flow chart illustrating an example method 720 offabricating the dental restoration 134 using the interference model 128.In some embodiments, the method 720 is performed at the restorationfabrication station 132. In this example, the method 720 includesoperations 722, 724, 726, and 728.

At operation 722, the dental restoration 134 is fabricated. In someembodiments, the dental restoration 134 is designed digitally andfabricated using the rapid fabrication machine 126. In otherembodiments, the dental restoration 134 is fabricated using moretraditional methods, such as hand waxing and lost casting, or porcelainstacking. Additionally, in some embodiments, operation 722 is performedusing the a wax-up of the dental restoration 134 rather than the dentalrestoration 134 itself.

At operation 724, the dental restoration 134 is compared to theinterference model 128.

At operation 726, it is determined whether the dental restoration 134interferes with the interference model 128. If so, the method 720continues to operation 728. If not, the method 720 ends.

At operation 728, the dental restoration 134 is adjusted. Afteroperation 728, the method returns to operation 724. This loop throughoperations 724-726 repeats until it is determined that the dentalrestoration 134 does not interfere with the interference model 128.

FIG. 20 is a flow chart illustrating an example method 750 of designingthe dental restoration data 124 using the interference model data 122.In some embodiments, the method 750 is performed by the design system118. In this example, the method 750 includes operations 752, 754, 756,and 758.

At operation 752, the dental restoration data 124 and the interferencemodel data 122 are received.

At operation 754, in some embodiments, a distance between a surfacerepresented by the dental restoration data 124 and a surface representedby the interference model data 122 is calculated. In some embodiments,the distance is calculated by determining for each vertex on the surfacerepresented by the dental restoration data 124 a nearest point on thesurface represented by the interference model data 122 and thencalculating the distance between the vertex and the point. In someembodiments, the distance is calculated as the length of a threedimensional vector between the vertex and the point. In otherembodiments, the distance is calculated as the length of the projectionof the three dimensional vector between the vertex and the point in theocclusal direction. In other embodiments, the distance is onlycalculated for vertices that intersect with surface represented by theinterference model data 122. Other embodiments are possible as well.

At operation 756, in some embodiments, colors are assigned to regions ofa surface represented by the dental restoration data 124 based on thedistances calculated in operation 754. In some embodiments, colors areassigned to each vertex of the dental restoration data 124. In otherembodiments, colors are assigned to each facet of the surfacerepresented by the dental restoration data 124. In yet otherembodiments, colors are assigned to only the facets or vertices thatintersect with the surface represented by the interference model data122. Other embodiments are possible as well.

At operation 758, the dental restorations represented by the dentalrestoration data 124 is visualized.

FIG. 21 is an illustration of a cross-sectional view of the interferencemodel data 122 and the dental restoration data 124. The interferencemodel data 122 includes an interference surface 790. The dentalrestoration data 124 includes an exterior surface 792 and an interiorsurface 794. In some embodiments, an illustration similar to FIG. 21 isdisplayed by a user interface of the design system 118.

The interference surface 790 is a three-dimensional surface thatrepresents the union of the opposing dentition O in multiple bitelocations. In some embodiments, the

The exterior surface 792 is a three-dimensional surface representing theexterior surface of the dental restoration 134. The interior surface 794is a three-dimensional surface representing the interior of the dentalrestoration 134. In some embodiments, the interior surface 794approximately follows the surface of the restoration site R. In someembodiments, the interior surface 794 is offset from the surface of therestoration site R by an offset amount, such as 10-200 micrometers.

In some embodiments, the interference surface 790 is compared to theexterior surface 792 to generate a color map representing theinterferences between the dental restoration data 124 and theinterference model data 122.

FIG. 22 is an illustration of a cross-sectional view of the dentalrestoration data 124 with an example embodiment of a color map 820 onthe exterior surface 792. The color map 820 includes regions 812, 814,816, and 818. In some embodiments, the illustration in FIG. 22 isdisplayed by a user interface of the design system 118.

In the example shown, the regions 812, 814, 816, and 818 are displayedin different colors that represent the distance between the regions andthe interference surface 790 (shown in FIG. 21). Although the embodimentshown in FIG. 22 includes four regions, other embodiments include moreor fewer regions.

In the example shown, the region 812 is colored a first color. Here, thefirst color indicates that the region 812 interferes with theinterference surface 790. For example, in some embodiments, the firstcolor indicates that the vertices in the region 812 intersect with(i.e., are inside of) the interference surface 790. In some embodiments,the first color also indicates that the vertices are very close tointerfering with the interference surface. For example, in someembodiments, the first color is used to indicate that a vertex eitherintersects with the interference surface 790 or is less than 10micrometers away from the interference surface 790. In this manner, thecolor map 820 allows for small errors in the impressioning and scanningprocesses. In some embodiments, the first color is color that indicatesto stop, such as red. In other embodiments, the first color is adifferent color.

In the example shown, the regions 814 and 818 are colored a secondcolor. Here, the second color indicates that the regions 814 and 818 areclose to interfering with the interference surface 790. For example, insome embodiments, the second color indicates that the vertices in theregions 814 and 818 are between 0 and 100 micrometers away from theinterference surface 790. In some embodiments, the second color is acolor that indicates to use caution, such as yellow or orange. In otherembodiments, the second color is a different color.

In the example shown, the region 812 is colored a third color. Here, thethird color indicates that the region 812 is not close to interferingwith the interference surface 790. For example, in some embodiments, thethird color indicates that the vertices in the region 812 are at least100 micrometers away from the interference surface 790. In someembodiments, the third color is a neutral color, such as white, gray,tan, or ivory. In other embodiments, the third color is a differentcolor.

Although, the color map 820 includes three colors, in other embodimentsmore or fewer colors are used. Additionally, in other embodiments, otherdistance ranges are used for the color map.

FIG. 23 is a schematic block diagram illustrating an example of a system900 for simulating incisal guide paths to fabricate a provisionalrestoration 914. In this example, the system 900 includes a dentaloffice 102. However, in other embodiments, the system 900 also includesa dental lab.

The example dental office 102 includes the dental impression station104, the motion capture station 106, the 3D scanner 116, a provisionaldesign system 902, the rapid fabrication machine 126, a provisionalrestoration fabrication station 912, and a provisional restorationinstallation station 916. Also shown are the dental impression 108,functional bite map 110, motion data 112, digital dental model 120,functional bite map data 121, provisional restoration mold data 904,incisal guide data 906, provisional restoration mold 908, incisal guidemodel 910, and provisional restoration 914. Additionally, the patient Pand the dentist D are shown.

Although shown as a single dental office in this figure, in someembodiments, the dental office 102 comprises multiple dental offices.For example, in some embodiments, one or more of the dental impressionstation 104, the motion capture station 106, the 3D scanner, theprovisional design system 902, the rapid fabrication machine 126, andthe provisional restoration fabrication station 912 are in a differentdental office than the provisional restoration installation station 916.Further, in some embodiments, one or more of the dental impressionstation 104, the motion capture station 106, the provisional designsystem 902, the rapid fabrication machine 126, the provisionalrestoration fabrication station 912, and the provisional restorationfabrication station 912 are not in a dental office.

The operation of the dental impression station 104, the motion capturestation 106, and the 3D scanner 116 has been described with system 100(shown in FIG. 1). These components operate in a similar manner insystem 900. However, in some embodiments, one or both of the motioncapture station 106 and the 3D scanner 116 are not included in thesystem 900. For example, in some embodiments, the digital dental model120 is generated at the dental impression station 104 using a digitalimpression system. In some of these embodiments, the 3D scanner is notincluded. Additionally, as will be described below, some embodiments donot require the motion data 112 or the functional bite map data 121 andthus the motion capture station 106 is not included.

The provisional design system 902 is a system that is configured togenerate one or both of provisional restoration mold data 904 and theincisal guide data 906. In some embodiments, the provisional restorationmold data 904 is three-dimensional digital data that represents theprovisional restoration mold 908 and is in a format suitable forfabrication using the rapid fabrication machine 126. Similarly, in someembodiments, the incisal guide data 906 is three-dimensional digitaldata that represents the incisal guide model 910 and is in a formatsuitable for fabrication using the rapid fabrication machine 126.

In some embodiments, the provisional design system 902 comprises acomputing device including user input devices. In some embodiments, theprovisional design system 902 includes computer-aided-design (CAD)software that generates a graphical display of one or both of theprovisional restoration mold data 904 and the incisal guide data 906 andallows an operator to interact with and manipulate one or both of theprovisional restoration mold data 904 and the incisal guide data 906. Insome embodiments, the provisional design system 902 comprises digitaltools that mimic the tools used by a laboratory technician to physicallydesign a provisional dental restoration. In some other embodiments, theprovisional design system 902 comprises a server that partially or fullyautomates the generation of designs of one or both of the provisionalrestoration mold data 904 and the incisal guide data 906.

In some embodiments, the provisional restoration mold 908 is used at theprovisional restoration fabrication station 912 to fabricate theprovisional restoration 914. In some embodiments, the provisionalrestoration fabrication station 912 and the provisional restorationinstallation station 916 are integrated and the provisional restorationmold 908 is used to fabricate the provisional restoration 914 in themouth of the patient P. In other embodiments, the incisal guide model910 is used at the provisional restoration fabrication station 912 tofabricate the provisional restoration 914 on an articulator.

In some embodiments, the provisional restoration 914 is seated in themouth of the patient P in the provisional restoration installationstation 916 by the dentist D.

FIG. 24 illustrates an exemplary architecture of the program modules 200and program data 202 of the provisional design system 902. The programmodules 200 include a plurality of modules that, when executed by theprocessing device 180 (shown in FIG. 2), perform one or more operationsof the provisional design system 902. The modules include a provisionalrestoration mold design engine 950 and an incisal guide engine 952. Insome embodiments, the program modules 200 includes more, fewer, ordifferent modules than those shown in FIG. 24.

The program data 202 is stored in a data storage device, such as thememory 182 or the secondary storage device 192 (shown in FIG. 2). Insome embodiments, program data 202 includes impression data 454, bitemovement data 456, provisional restoration mold data 904, and incisalguide data 906. In some embodiments, the program data 202 include more,fewer, or different types of data than the data shown in FIG. 9.

In some embodiments, the data stored in program data 202 can berepresented in one or more files having any format usable by a computer.Examples include text files formatted according to a markup language andhaving data items and tags to instruct computer programs and processeshow to use and present the data item. Examples of such formats includehtml, xml, and xhtml, although other formats for text files can be used.Additionally, the data can be represented using formats other than thoseconforming to a markup language.

The provisional restoration mold design engine 950 operates to generatethe provisional restoration mold data 904. In some embodiments, theprovisional restoration mold design engine 950 uses the impression data454 and the bite movement data 456 to generate the provisionalrestoration mold data 904.

The incisal guide engine 952 operates to generate the incisal guide data906. In some embodiments, the incisal guide engine 952 uses theimpression data 454 and the bite movement data 456 to generate theincisal guide data 906.

FIG. 25 is a flow chart illustrating an example method 990 of using thesystem 900 to fabricate and install the provisional restoration 914. Insome embodiments, the method 990 is performed in the dental office 102.In other embodiments, the method 990 is performed in multiple locations,such as one or more dental offices and dental laboratories. In thisexample, the method 990 includes operations 992, 994, 996, and 998.

At operation 992, the dental impression 108 is captured. At operation994, the digital dental model 120 is generated. In some embodiments, thedigital dental model 120 is generated by using the 3D scanner 116 toscan the dental impression 108. In other embodiments, the dentalimpression station 104 generates the digital dental model 120 directly.

At operation 996, the provisional restoration mold 908 is fabricated. Insome embodiments, the provisional restoration mold 908 is fabricated bythe rapid fabrication machine 126 using the provisional restoration molddata 904. In some embodiments, the provisional restoration mold data 904is generated by the provisional design system 902 using the digitaldental model 120. In some embodiments, the provisional design system 902also uses one or both of the functional bite map data 121 and motiondata 112 to generate the provisional restoration mold data 904.

At operation 998, the provisional restoration 914 is fabricated andinstalled in the patient P's mouth using the provisional restorationmold 908. In some embodiments, the provisional restoration 914 isfabricated by filling the provisional restoration mold 908 with aprovisional material such as an acrylic resin or bis-acrylic. Someexamples of acrylic resins include polymetheyl methacrylate andpolyethyl methacrylate. In some embodiments, other materials are used aswell.

In some embodiments, once the provisional restoration mold 908 is filledwith the provisional material, the provisional restoration mold 908 isplaced over the restoration site in the patient P's mouth. In someembodiments, the provisional restoration mold 908 is aligned with therestoration site using landmarks or contours of adjacent teeth. Afterthe provisional material has hardened, the provisional restoration mold908 is removed. In some embodiments, the dentist D adjusts and polishesthe provisional material to finish the provisional restoration 914.

FIG. 26 is a flow chart illustrating another example method 1030 ofusing the system 900 to fabricate and install the provisionalrestoration 914. In some embodiments, the method 1030 is performed inthe dental office 102. In other embodiments, the method 1030 isperformed in multiple locations, such as one or more dental offices anddental laboratories. In this example, the method 1030 includesoperations 1032, 1034, 1036, and 998.

At operation 1032, the pre-preparation dental impression is captured.The pre-preparation dental impression represents the dentition of thepatient P before the dentist has prepared the restoration site for theprovisional restoration 914. In some embodiments, the pre-preparationdental impression provides information regarding the proper anatomy andcontour of the provisional restoration 914. The pre-preparation dentalimpression can be captured using any digital or physical impressiontechniques that are used to capture dental impressions.

At operation 1034, the provisional restoration mold 908 is fabricatedusing the pre-preparation dental impression. In some embodiments, theinterior surface of the provisional restoration mold 908 is fabricatedto match the surface of the pre-preparation dentition at the restorationsite. Additionally, in some embodiments, the interior surface of theprovisional restoration mold 908 is fabricated to match the surface ofthe pre-preparation dentition with an offset. For example, in someembodiments, the interior surface of the provisional restoration mold908 is offset from the surface of the pre-preparation dentition by20-100 micrometers.

Additionally, in some embodiments, the interior surface of theprovisional restoration mold 908 is shifted in the vertical dimension byan amount corresponding to a desired change in the vertical dimension ofocclusion of the patient's dentition. The vertical dimension ofocclusion refers to the distance between the maxilla and mandible whenin maximum intercuspation.

In some embodiments, the dentist D may desire to increase the verticaldimension of occlusion of the patient P by 1 mm. The dentist D mayaccomplish this by increasing the height of the dentition at one more ofthe contact locations during maximum intercuspation using one or morerestorations. Conversely, the dentist D may desire to lower the verticaldimension of occlusion of the P by 1 mm instead. The dentist D mayaccomplish this by removing dentition to lower the height of one or moreof the contact locations during maximum intercuspation. In either case,in some embodiments, the interior surface of the provisional restorationmold is shifted by a corresponding amount in the vertical dimension aswell. In this manner, the contour of the provisional restoration 914matches the original contour and is located in the same positionrelative to the opposing dentition even after the vertical dimension ofocclusion is adjusted.

At operation 1036, the dentist D prepares the restoration site. In someembodiments, the dentist D prepares the restoration site by removingsome of the structure of the patient P's dentition so that therestoration site is prepared to receive a dental restoration.

Next, at operation 998, the provisional restoration 914 is fabricatedand installed in the patient P's mouth using the provisional restorationmold 908.

FIG. 27 is a flow chart illustrating an example method 1080 of using thesystem 900 to fabricate a dental restoration based on the provisionalrestoration 914. In some embodiments, the method 1080 is performed inthe dental office 102. In other embodiments, the method 1080 isperformed in multiple locations, such as one or more dental offices anddental laboratories. In this example, the method 1080 includesoperations 1082, 1084, 1086, and 1088.

At operation 1082 the provisional restoration 914 is installed in thepatient P. In some embodiments, the provisional restoration 914 isfabricated and installed using the method 1030 (shown in FIG. 26). Inother embodiments, the provisional restoration 914 is fabricated usingthe method 990 (shown in FIG. 25). In other embodiments, the provisionalrestoration 914 is fabricated using other methods.

At operation 1084, the provisional restoration 914 is evaluated in thepatient P's mouth. In some embodiments, the patient P wears theprovisional restoration 914 for an evaluation time period and providesfeedback to the doctor D. Additionally, in some embodiments, the doctorD inspects the provisional restoration 914 for signs of wear after theevaluation time period.

At operation 1086, it is determined whether the provisional restoration914 is satisfactory. In some embodiments, the doctor D determineswhether the provisional restoration 914 is satisfactory based on theevaluation of operation 1084. If the provisional restoration 914 issatisfactory, the method 1080 continues to operation 1090. If theprovisional restoration 914 is not satisfactory the method 1080continues to operation 1088.

At operation 1088, the provisional restoration 914 is adjusted orreplaced. In some embodiments, the provisional restoration 914 isadjusted using an abrasive wheel or another carving tool without beingremoved from the patient P's mouth. In other embodiments, theprovisional restoration mold data 904 is adjusted using the provisionaldesign system 902. In these embodiments, the provisional restorationmold data 904 is adjusted based on the evaluation of operation 1084.Then, the provisional restoration mold 908 is fabricated by the rapidfabrication machine 126 using the provisional restoration mold data 904after it has been adjusted. Then, the provisional restoration mold 908is used to fabricate and install a new provisional restoration. Afterthe provisional restoration 914 is adjusted or replaced, the method 1080returns to operation 1084 so that the new provisional restoration can beevaluated.

At operation 1090, a dental restoration is fabricated based on theprovisional restoration 914. In some embodiments, the dental restorationis fabricated using data acquired by scanning the provisionalrestoration 914 with the 3D scanner 116. In other embodiments, thedental restoration is fabricated using the provisional restoration molddata 904. In some embodiments, one or both of the provisionalrestoration mold data 904 and the data acquired by scanning theprovisional restoration 914 are used by the design system 118 (shown inFIG. 1) to design the dental restoration data 124. The dentalrestoration data 124 is then used to fabricate the dental restoration134.

FIG. 28 is a cross-sectional illustration of the anterior dentition ofthe patient P. The tooth T and the opposing dentition O are shown. Thetooth T represents a tooth that the dentist D intends to replace orrepair with a restoration. The opposing dentition O represents theopposing tooth or teeth on the opposite arch of the tooth T.

Also shown is the original contour C and the incisal guide path G. Theoriginal contour C represents the surface of the tooth T prior to beingworn away by the opposing dentition O. The incisal guide path Grepresents the worn surface of the tooth T.

In some embodiments, the shape of the incisal guide path G is preservedwhen the tooth T is replaced by the provisional restoration 914 or thedental restoration 134. In some embodiments, by preserving the incisalguide path G the provisional restoration 914 and the dental restoration134 fit more harmoniously with the opposing dentition O and are lesslikely to fracture due to wear from the opposing dentition O. In someembodiments, the provisional restoration mold 908 is fabricated with aninterior contour that preserves the incisal guide path G.

FIG. 29 is an illustration of an example of an embodiment 908 a of theprovisional restoration mold 908. The provisional restoration mold 908 aincludes an interior surface 1130, including incisal guide path surface1132, exterior surface 1134, and registration structures 1136 a-b,including registration surfaces 1138 a-b. In some embodiments, theprovisional restoration mold 908 a is formed from a bio-compatiblematerial that is safe for temporary in-mouth placement. For example, insome embodiments, the provisional restoration mold 908 a is formed bythe rapid fabrication machine 126 from an acrylic material such asObject MED610, available from STRATSYS LTD. of Eden Prairie, Minn.

The interior surface 1130 operates to define the shape of some or all ofthe exterior surface of the provisional restoration 914. In someembodiments, the incisal guide path surface 1132 matches the contour ofthe incisal guide path G. In some embodiments, the incisal guide pathsurface 1132 is offset vertically to compensate for an adjustment to thepatient P's vertical dimension of occlusion.

The exterior surface 1134 is offset from the interior surface 1130 toform the walls of the provisional restoration mold. In some embodiments,the exterior surface 1134 is offset from the interior surface 1130uniformly to generate walls with substantially uniform thickness. Inother embodiments, the exterior surface 1134 is offset from the interiorsurface 1130 non-uniformly to generate walls with a non-uniformthickness. For example, in some embodiments, the exterior surface 1134is offset from the interior surface 1130 by a smaller distance in theinterproximal walls than on the labial and lingual walls of theprovisional restoration mold 908 a.

The registration structures 1136 a-b operate to align the provisionalrestoration mold 908 a. In some embodiments, the registration surfaces1138 a-b match the labial surfaces of the dentition adjacent to therestoration site. In some embodiments, the registration surfaces 1138a-b are configured to be fit against a specific portion of the labialsurfaces of the dentition adjacent to the restoration site. In thismanner, the dentist D can determine that the provisional restorationmold 908 a is properly aligned with the prep site when the registrationsurfaces 1138 a-b fit properly against the dentition adjacent to therestoration site. Although two of the registration structures 1136 a-bare included in the embodiment of the provisional restoration mold 908 ashown in FIG. 29, in other embodiments more or fewer registrationstructures are included. Additionally, in some embodiments, otherregistration structures are used to align the provisional restorationmold 908 a with the restoration site.

FIG. 30 is an illustration of an alternative embodiment 908 b of theprovisional restoration mold 908. The embodiment shown in FIG. 30 issimilar to the embodiment 908 a shown in FIG. 29.

The embodiment shown in FIG. 30 includes a registration structure 1142,including registration surface 1144. Additionally, the interior surface1130 and the exterior surface 1134 do not fully surround the restorationsite. Instead, the interior surface 1130 and the exterior surface 1134are open along the proximal walls. In some embodiments, this allows theprovisional restoration to be formed in contact with the adjacentdentition.

The registration structure 1142 is a physical structure configured toalign the provisional restoration mold 908 b with the restoration site.In some embodiments, the registration surface 1144 matches the incisaledge of the adjacent dentition. In this manner, the dentist D candetermine that the provisional restoration mold 908 b is properlyaligned with restoration site when the provisional restoration mold isfully seated on the adjacent dentition. Although only one registrationstructure 1142 is shown in FIG. 30, other embodiments include additionalregistration structures.

FIG. 31 is a cross-sectional illustration of a provisional restorationmold 908 being used to form a provisional restoration 914 on arestoration site R. As shown in this figure, the incisal guide pathsurface 1132 of the provisional restoration mold 908 generates anincisal guide path G on the provisional restoration 914 that matches theoriginal incisal guide path.

FIG. 32 is a cross-sectional illustration of an articulator 1200 beingused with an incisal guide model 910. In some embodiments, thearticulator 1200 includes a lower structure 1202, an upper structure1204, and a vertical support 1206, including a socket 1208.

The lower structure 1202 is a rigid structure and includes a lower modelmounting plate 1210 and an incisal guide model mounting plate 1212. Thelower model mounting plate 1210 operates to secure a lower arch dentalmodel 1214 to the articulator 1200. The incisal guide model mountingplate 1212 operates to secure an incisal guide model 910 to thearticulator 1200.

The upper structure 1204 is a rigid structure and includes an uppermodel mounting plate 1216 and a guide pin 1218. The upper model mountingplate 1216 operates to secure an upper arch dental model 1220 to thearticulator 1200. The guide pin 1218 is a rigid structure that includesa tip 1222. The guide pin 1218 is rigidly secured to the upper structure1204 and is configured to be immovable relative to the upper structure1204 during operation of the articulator 1200. The tip 1222 of the guidepin 1218 is configured to move along the surface of the incisal guidemodel 910. As the guide pin 1218 moves along the surface of the incisalguide model 910, the upper structure 1204 and the upper arch dentalmodel 1220 move in a manner that replicates the motion of the patientP's jaw.

The vertical support 1206 is a rigid structure that is rigidly coupledto the lower structure 1202 and is configured to be immovable relativeto the lower structure 1202 during operation of the articulator 1200.The vertical support 1206 includes a socket 1208. The socket isconfigured to couple with the upper structure 1204. In some embodiments,the socket 1208 is configured to allow the upper structure 1204 torotate and move while remaining coupled. In this manner, the socket 1208approximates the condyle of the patient's jaw.

The incisal guide model 910 is a model that forms a surface thatcorresponds to the incisal guide path G. In some embodiments, as theguide pin 1218 moves across the surface of the incisal guide model 910,the upper arch dental model 1220 moves relative to the lower arch dentalmodel 1214 in a manner that is similar to the actual motion of thepatient P's jaw. In some embodiments, as the guide pin 1218 moves acrossthe incisal guide model 910, a surface of the upper arch dental model1220 that corresponds to the incisal guide path G contacts the lowerarch dental model 1214. In this manner, the provisional restoration 914can be fabricated on the articulator to preserve the incisal guide pathG.

In some embodiments, the incisal guide model 910 is fabricated using therapid fabrication machine 126 based on the incisal guide data 906. Insome embodiments, the provisional design system 902 generates theincisal guide data 906 from the digital dental model 120. In otherembodiments, the provisional design system 902 generates the incisalguide data 906 by moving the lower arch along the paths defined in themotion data. In some embodiments, the incisal guide data 906 isgenerated by sweeping the lower arch model data through all of the bitepositions recorded in the functional bite map data 121 or the motiondata 112. Additionally, in some embodiments, the incisal guide data 906is generated from a pre-preparation impression of the lingual surface ofthe upper arch of the patient P. In some embodiments, the incisal guidedata 906 is formed by inverting the lingual surface of the upper arch ofthe patient P. Similarly, in some embodiments, the incisal guide data906 is formed by inverting the surface formed by sweeping the lower archmodel through all of the bite positions and paths. In this manner, theincisal guide model 910 forms a surface that causes motion on thearticulator that mimics the motion captured from the patient. Otherembodiments are possible as well.

In some embodiments, the incisal guide model 910 includes one or moreretention structures 1224 and 1226. The retention structures 1224 and1226 are configured to align and secure the incisal guide model 910 tothe articulator 1200.

In the example shown, the retention structure 1224 comprises a peg thatis configured to fit in a corresponding hole in the incisal guide modelmounting plate 1212. In some embodiments, the retention structure 1224includes a registration grove or ridge to properly align the incisalguide model 910 to the incisal guide model mounting plate 1212. In theexample shown, the retention structure 1226 comprises a clip that isconfigured to fit around the edge of the incisal guide model mountingplate 1212.

In some embodiments, the retention structures 1224 and 1226 are includedin the incisal guide data. Additionally, some embodiments include more,fewer, or different retention structures.

Some embodiments include one or more of the following:

A method of generating a dental restoration to restore an anterior toothof a patient, comprising: generating an incisal guide path, using acomputing device, corresponding to the lingual surface of the anteriortooth; fabricating an incisal guide path structure based on the incisalguide path; and using the incisal guide path structure to generate thedental restoration.

The method, wherein the dental restoration is a provisional restoration.

The method, wherein the dental restoration is a permanent restoration.

The method, wherein the incisal guide path structure is a moldconfigured to be filled with a provisional material and placed over therestoration site, wherein the mold comprises a cavity and an alignmentstructure, the cavity being defined by an interior surface of the mold,a portion of the interior surface having a contour that matches theincisal guide path, and the alignment structure being configured toalign the mold with the restoration site.

The method, wherein the incisal guide path structure is an incisal guideplane configured to direct the movement of an articulator configured toarticulate a physical dental model representing a dentition of thepatient.

The method, wherein the incisal guide path is generated from anpre-preparation impression of the anterior tooth.

The method, wherein the incisal guide path is generated using animpression of a dentition of the patient and motion data correspondingto the positions of an upper arch of the dentition of the patientrelative to a lower arch of the dentition of the patient.

The various embodiments described above are provided by way ofillustration only and should not be construed to limit the claimsattached hereto. Those skilled in the art will readily recognize variousmodifications and changes that may be made without following the exampleembodiments and applications illustrated and described herein, andwithout departing from the true spirit and scope of the followingclaims.

What is claimed is:
 1. A system for fabricating a dental restoration torestore a tooth at a restoration site in a dentition of a patient,wherein the dentition includes a restoration dental arch and an opposingdental arch, the restoration dental arch including the restoration siteand the opposing dental arch being opposite the restoration dental arch,comprising: an impression apparatus configured to capture an impressionof the dentition of the patient, the portion of the dentition includingthe restoration site; a motion capture apparatus configured to capture aplurality of location data points, the location data points representingthe locations of the opposing dental arch relative to the restorationdental arch as the dentition moves between a plurality of bitepositions; an interference model generation system configured togenerate an interference model for the restoration site, wherein theinterference model includes an interference surface, the interferencesurface corresponding to the locations of a portion of the opposingdental arch in at least a portion of the plurality of the locationsrepresented by the plurality of location data points; and a restorationdesign system for designing a restoration using the interference model.2. The system of claim 1, wherein the impression apparatus is anintraoral scanner.
 3. The system of claim 1, wherein the impressionapparatus comprises an impression material.
 4. The system of claim 3,wherein the impression material includes at least one of sodium alginateand vinyl polysiloxane.
 5. The system of claim 1, further comprising arapid fabrication machine configured to fabricate a physicalinterference model from the interference model.
 6. The system of claim1, wherein the restoration design system includes a computing device,the computing device comprising a processing device and acomputer-readable storage device.
 7. The system of claim 6, wherein therestoration design system identifies interferences between therestoration and the interference model as regions of intersectionbetween the restoration and the interference model.
 8. The system ofclaim 6, wherein the processing device is configured to generate a userinterface that includes a graphical representation of the restorationand the interference model.
 9. The system of claim 8, wherein the userinterface includes a color map to represent interferences between therestoration and the interference model.
 10. The system of claim 1,wherein the motion capture apparatus is formed from a bite registrationmaterial.
 11. A method of generating a dental restoration for a patient,comprising: generating an interference model from an impression and afunctional bite map, the impression representing at least a portion of adentition of the patient, the functional bite map representing biteregistration information for a plurality of positions of the dentitionof the patient; aligning the interference model to a restoration site ofthe patient; and designing a dental restoration for the restoration siteusing the interference model.
 12. The method of claim 11, furthercomprising fabricating a physical dental model using the impression,wherein the physical dental model includes at least a portion of thedentition of the patient.
 13. The method of claim 12, further comprisingfabricating a physical interference model using a rapid fabricationmachine.
 14. The method of claim 13, wherein the physical interferencemodel includes a retention structure configured to align and secure thephysical interference model to the physical dental model.
 15. The methodof claim 14, further comprising placing the dental restoration on thephysical dental model, securing the physical interference model to thephysical dental model, and checking for interferences between the dentalrestoration and the physical interference model.
 16. The method of claim15, further comprising adjusting the dental restoration to remove atleast a portion of the interferences between the dental restoration andthe physical interference model.
 17. The method of claim 11, furthercomprising scanning a physical functional bite map using a 3D scanner togenerate the functional bite map.
 18. The method of claim 11, whereinthe physical functional bite map comprises a securing layer and a bitecapture layer, the securing layer being configured to secure thephysical functional bite map to a first dental arch of the dentition ofthe patient, the bite capture layer being configured to capture indentscorresponding to the location of a second dental arch of the dentitionof the patient relative to the first dental arch.